Outdoor flooring, deck and patio surface system and method

ABSTRACT

A system and method for providing an outdoor flooring such as a lightweight deck surface, employs a fiber reinforced polymer structural panel with plural grid openings therein. A fastener is driven into selected openings to enable the panel to be secured to a deck frame. A surfacing material, such as a quarried stone, is attached to the top of the panel, providing a stone deck surface without requiring substantial structural support.

BACKGROUND OF THE INVENTION

This invention relates to outdoor flooring, surfaces for decks, patiosand the like, and more particularly, to a decking system and method forenabling use of surface materials that would ordinarily lack suitablestructural features to accommodate deck or patio applications.

Stone walkway and step surfaces are frequently used at homes andbusinesses, as the appearance is attractive and enjoyed by many. Walkwayand step stones are typically rather thick, to provide sufficientstructural properties to support weight necessary in walkway and stepuse. As such, given the weight of stone, elevated deck surfaces such asfor home decks, do not employ stone surfaces, as the weight of the stonerequires substantially structural support beyond what is typicallyemployed for deck construction.

SUMMARY OF THE INVENTION

In accordance with the invention, a deck and patio surface systemcomprises a fiber reinforced structural panel employed as a substrate, amounting fastener for enabling the panel to be secured to a deck, patio,or the like, and a surfacing material bonded or otherwise attached tothe structural panel.

Accordingly, it is an object of the present invention to provide animproved deck system to enable use of stone surface in above-ground deckapplications.

It is a further object of the present invention to provide an improvedsystem for deck or patio applications to allow use of surface materialnot normally by itself having sufficient structural properties for suchuse.

It is yet another object of the present invention to provide an improvedmethod for providing a deck surface.

Another object of the present invention is to provide a deck or patiosystem adapted for use over waterproofed living space without requiringpenetration of the waterproof membrane.

It is still another object of the present invention to provide a systemand method for providing a new surface over an existing damaged patiosurface.

The subject matter of the present invention is particularly pointed outand distinctly claimed in the concluding portion of this specification.However, both the organization and method of operation, together withfurther advantages and objects thereof, may best be understood byreference to the following description taken in connection withaccompanying drawings wherein like reference characters refer to likeelements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a portion of the systemaccording to the invention;

FIG. 2 is a top view of the fastener of FIG. 1, during an initialforming phase;

FIG. 3 is a top view of the fastener of FIG. 2 when formed to finalshape;

FIG. 4 is a sectional view of the fastener of FIG. 3 taken along line4-4 of FIG. 3;

FIG. 5 is a side view of the fastener of FIG. 3 taken in the directionof arrow 5 of FIG. 3;

FIGS. 6-19 are illustrations of the steps of the method of installing adeck system in accordance with the invention.

DETAILED DESCRIPTION

The system according to a preferred embodiment of the present inventioncomprises a composite deck surface having a structural panel, fastenerelements to secure the structural panel to a deck base, and a surfacingmaterial bonded to the structural panel.

Referring to FIG. 1, an exploded perspective view of a portion of thesystem 10, a structural panel 12, suitably comprising a fiber reinforcedpolymer panel having a grid pattern of openings 14 in the illustratedembodiment, is adapted to be received on top of a deck base structure,which may suitably comprise wood deck framing timbers 16. A fastenerelement 18, described in further detail in connection with FIGS. 2-5herein, is adapted to be received in an opening 14 so as to engage withthe structural panel 12, seating such that the top surface of thefastener is below the top surface of the panel 12. The fastener includesa central hole 20 adapted to receive a fastener therethrough, to allowsecuring the panel to the deck framing timber 16.

A surfacing material 22, which may comprise a cut stone having anaesthetically pleasing appearance, color and/or pattern, is suitablybonded to the structural panel, using a bonding material 24, forexample. The surfacing material may also comprise tile, dry laid brick,concrete or stone pavers, for example.

The structural panel is suitably provided in sheets having dimensions of4 foot by 8 foot, with a 1.5 inch square grid size, in the illustratedembodiment. The panel is suitably approximately 1 inch thick. Theindividual grid openings narrow somewhat from the top of the panel tothe bottom, such that they are wider at the top face than at the bottom.In the particular embodiment, the opening is 1- 5/16^(th) inch at thetop measured from interior edge to the opposite edge of an individualgrid opening, but is 11-¼^(th) inch at the bottom face of the panel.

A suitable panel that is employed with the system and method may be afiber reinforced general purpose polyester molded resin panel, althoughother materials may be used. The panel size is preferably 4 foot by 8foot in the preferred embodiment, based on construction standards andpractices, but may be otherwise re-sized to the desired dimensions,within a 1/16^(th) inch tolerance, so as to provide a system thatfunctions with 16 inch framing dimensions typically used in deckapplications. The panel can be provided in other sizes than theillustrated example, chosen to have sufficient support while spanningthe supporting elements supporting the panel. Preferably the panel is apre-configured dimensional size suitable for compliance with customarybuilding practices.

Referring now to FIGS. 2-5, which are views illustrating the fastener 18and explaining how it is manufactured, the fastener in a preferredembodiment is made of a stainless steel material, stamped to the shapeshown in FIG. 2. The fastener is provided with a row series of twelveteeth 26 on each of 2 sides thereof in a central region, as well as acorner tooth 28 at each of the four peripheral corners of the fastener.The corner teeth 28 are on extended arm portions 34 of the fastenerhaving a slight taper inwardly on the outer faces thereof, and anarcuate shape on the inward sides thereof. Teeth 26 and 28 are suitably3/64^(th) inch in height. A central hole 30 is provided in the fastener,as are two side tabs 32 on opposing sides, next to the sides carryingthe rows of teeth. A slight notch is defined between the tabs 32 and thearm portions 34.

After the fastener is formed as in FIG. 2, it is then bent along lines36, approximately 90 degrees downwardly, to provide the configurationvisible in FIG. 1 and 5, where the arm portions 34 and teeth 28 form“legs”. The central portion of the fastener about hold 30 is countersunkto provide a 17/32 inch inner diameter flat bottom countersink, forreceiving a fastener head discussed below.

In employing the system to provide a deck or patio surface, theinstallation steps illustrated in FIG. 6-19 are employed. The exampleshown in FIGS. 6-19 is in a deck installation, where a wood frame deckis present and the system is installed thereon.

Referring to FIG. 6, first, a waterproof membrane 38, such as a 40 milbituminous based material, is placed over the wood framing to protectthe framing from water damage over time. Next, in FIG. 7, pluralstructural panels are cut and positions as necessary to fit over thearea of the deck framing that the system is to be installed upon. Next,(FIG. 8) fasteners 18 are placed into openings 14 in the structuralpanel in locations where the panel is to be secured to the frame 16. Thefasteners are tapped with a hammer so as to have the top surface of thefasteners be flush with the top surface of the structural panel. Next,as shown in FIG. 9, a punch (e.g., a ½ inch punch) is used with a hammerto set the fastener in the structural panel. Use of the punch results inthe teeth of the fastener “biting” into the inner walls of the openingin the structural panel, as well as setting the fastener to be below thetop surface of the structural panel.

Referring now to FIG. 10, a bead of adhesive material (for example,fiberglass adhesive) is applied between the joints of the panelsections. Stainless steel screws are then screwed through the openings30 in each fastener, to secure the structural panels to the deck frame16, as shown in FIG. 11 and 12, FIG. 12 being a split view showing botha close up view of a single secured fastener/screw and a father awayview illustrating a wider area, with 5 fasteners visible.

An edge trim 40 may now be applied to the peripheral edges of theassembled structural panel group, by cutting the trim to length andapplying adhesive thereto (to the inside corners of the edge trim) andthen mounting the edge trim to the edges of the panels (FIGS. 13-15).The edge trim can be, for example, metal edge trim and may be providedin a variety of colors and finishes, as desired for the aesthetic tasteof the user.

The surface material 22 is now prepared and applied to the structuralpanel, illustrated in FIGS. 16-18. In the illustrated embodiment,surfacing material 22 comprises quarried stone tiles having dimensionsof 15-¾ inch by 15-¾ inch, and approximately 11/32^(nd) inch thickness.The surface material tiles are first dry set and cut to fit around anyobstacles 42 (a vertical post in FIG. 16). Next, an adhesive is appliedto the back of the stones and spread with a notched trowel in theparticular embodiment shown. The adhesive suitably comprises Hold-Titebrand adhesive, suitably an elastomeric polymer. The surface material isnow placed adhesive side down onto the structural panel surface,positioned suitably with ⅛^(th) inch spacing between the tiles. Thejoints between tiles are not grouted, but are left open, allowingdrainage and room for expansion and providing an appearance that isvisually appealing. FIG. 18 illustrates the steps of placing the tilesin left, middle and right portions. FIG. 19 illustrates a finished decksurface employing stone tiles as the surfacing material, with edge trimon the peripheral edges of the structural panel.

In an alternative embodiment, the bonding material 24 is provided in theform of a sheet membrane 24′, such as an EPDM rubber or similarmaterial, which is flexible and soft. The sheet is suitably 1/16^(th)inch thick, of dimensions corresponding to those of the surfacingmaterial 22, and is coated on both sides with a pressure sensitivecontact adhesive. The sheet membrane 24′ is placed onto the surfacingmaterial 22 and then the surfacing material is placed onto thestructural panel 12. This alternative manner of adhering the material tothe panel results in a flexible bond.

Accordingly, as system and method are provided whereby a deck surface ofquarried stone is feasible. The use of the fiber reinforced polymerstructural panels, the fasteners and the adhering of the stone tilesresults in a lightweight high strength system weighing only 8 to 10pounds per square foot in the preferred embodiment. The bonding of thesurface material to the structural panel provides further strength tothe overall system. As noted above, other surface materials may beemployed, including but not limited to tile, brick, concrete and stonepavers.

Under an ASTM #E72-98 test, an exemplary system withstood 6282 lbs. offorce with no failure, a maximum 1.47″ deflection and a maximum 0.35″set deflection.

The preferred material for the surfacing material 22 is natural quarriedstone, which includes slates, quartz and sandstone. All stones aresuitably from deep cuts producing the highest quality and highestdensity stone for exterior applications.

In preferred embodiments, all stones have an ASTM #C121 Water Absorptionof 0.10%-0.37%. and an ASTM #C1026 Freeze Thaw unaffected rating or anatural resistance to damage under these conditions. Generally allstones have an ASTM #1028 Coefficient of Friction equal to or greaterthan most wood or composite products, so as to not be overly slippery asa walking surface. In most cases sealing of the surface is not requireddue to the high density of this material. However, sealing can enhancethe natural beauty if applied, but it is not required for long termdurability.

Although the illustrated embodiment shows an outdoor flooring system usefor a deck surface mounted to a wood frame, other uses are alsopossible. For example, the system and method can be employed as groundlevel patios, either as new construction or to cover a cracked orotherwise undesirable patio, providing positive drainage. Application tosteps is also another use. Further, the system and method can beemployed over waterproofed living spaces, for example, by placing thestructural panels over the top of the waterproof deck on sleepers(horizontal structural member on or near the ground that support weight)as a level, floating deck, without penetrating the waterproof membrane.

While a preferred embodiment of the present invention has been shown anddescribed, it will be apparent to those skilled in the art that manychanges and modifications may be made without departing from theinvention in its broader aspects. The appended claims are thereforeintended to cover all such changes and modifications as fall within thetrue spirit and scope of the invention.

1. An outdoor flooring system system, comprising: a composite surface,said composite surface comprising a structural panel member adapted formounting as a base framework; and a surface material adapted forattachment to a top surface of the structural panel to provide aflooring surface.
 2. The system according to claim 1, wherein saidstructural panel member comprises a fiber reinforced polymer panel. 3.The system according to claim 2, wherein said structural panel member isformed with plural openings therein.
 4. The system according to claim 3,wherein said plural openings form a grid pattern.
 5. The systemaccording to claim 3, wherein ones of said plural openings aresubstantially rectangular in shape.
 6. The system according to claim 3,wherein ones of said plural openings are substantially square in shape.7. The system according to claim 1, wherein said surface materialcomprises a stone.
 8. The system according to claim 7, wherein saidstone comprises a quarried stone.
 9. The system according to claim 1,wherein said surface material is selected from the group consisting oftile, brick, concrete or stone pavers.
 10. The system according to claim1, further comprising an adhesive between said structural panel memberand said surface material for adhering said surface material to saidstructural panel member.
 11. The system according to claim 10, whereinsaid adhesive comprises a flexible layer having a first face foradhering to said structural panel and a second face for adhering to saidsurface material, said first and second faces including a pressuresensitive contact adhesive thereon.
 12. A method of providing a flooringsurface, comprising the steps of: mounting a structural panel member toa framework; and attaching a surface material to a top surface of thestructural panel to provide a flooring surface.
 13. The method accordingto claim 12, wherein said structural panel member comprises a fiberreinforced polymer panel.
 14. The method according to claim 13, whereinsaid structural panel member is formed with plural openings therein. 15.The method according to claim 14, wherein said plural openings form agrid pattern.
 16. The method according to claim 14, wherein ones of saidplural openings are substantially rectangular in shape.
 17. The methodaccording to claim 14, wherein ones of said plural openings aresubstantially square in shape.
 18. The method according to claim 12,wherein said surface material comprises a stone.
 19. The methodaccording to claim 18, wherein said stone comprises a quarried stone.20. The method according to claim 12, wherein said attaching comprisesproviding a flexible sheet membrane with pressure sensitive adhesivethereon, and positioning said flexible sheet membrane between saidstructural panel and said surface material.
 21. A fastener for use insecuring two elements, comprising: a top surface having plural toothmembers on at least two opposite sides thereof; at least two downwardlyextending leg members, on opposite sides, having outwardly extendingteeth at a distal end thereof.